Integrated lubrication module for compressors

ABSTRACT

In accordance with certain embodiments, the present invention provides a modular approach to a lubrication package. Certain components such as the filter and cooler are directly connected to a block that has connections to accept them and internal porting to establish the proper flow paths for circulation, cooling and filtration of the circulating lubricant. The block can accept one or more coolers and one or more filters. The isolation valving for redundant equipment can also be integrated into the block. Many connections that had been used in past designs for the piping network are integrated into the block. The block can also be close mounted to the reservoir while a submersible pump further saves space and piping connections. Indeed, having the ability to maintain mechanical equipment (e.g., remove and replace filters and coolers) without shutting down, allows for continuous process flow, which eliminates down-town scheduling, loss of product and/or redundant backup, all of which comes at a considerable cost.

BACKGROUND

The field of this invention is compressors packaged with lubricationsystems that typically include a lubricant reservoir, circulationequipment, cooling equipment, filtration equipment and associatedcontrols, for example.

Typically, compressors are packaged in one or more skids to reduceinstallation time in the field. A typical assembly for a multi-stagecentrifugal compressor package will include the compressors and theintercoolers for the compressed gas, a lubrication system for thecompressors, as well as a drive system and associated gearbox to drivethe various stages, for example. These assemblies can also featureredundant equipment so that maintenance can go on with the compressorrunning. For example, in the lubrication system there can be dualcirculation pumps, coolers, filters and associated controls. Even ifprepackaged by the original equipment manufacturer, the lubricationsystem has literally hundreds of connections to complete the lubricationpiping as well as the coolant piping and the associated instrumentationand control connections. Apart from the issue of the sheer number ofconnections is the question of how much space is taken up by variouscomponents. Frequently, because of shipping requirements to remotelocations, the physical size and footprint of the overall package andits components are factors. Moreover, such concerns arise not onlyduring transport but also because of space constraints at the ultimatedestination. This is particularly the case in an offshore rigenvironment.

Some space saving advances have been made. FIG. 1 illustrates a priordesign showing an oil tank 10 and two shell and tube oil coolers 12 and14 and an oil pump 16. Just some of the interconnecting piping is shownin this view. While some space has been saved in more recent modules byreplacing the shell and tube coolers with brazed plate designs that takeup considerably less volume, the number of connections has not beenmarkedly reduced, and opportunities exist to economize on space andreduce the number of connections.

SUMMARY OF THE INVENTION

In accordance with certain embodiments, the present invention addressessuch issues and, as those skilled in the art will appreciate, providessolutions for rapid assembly with fewer connections while packaging thecomponents in a smaller occupied volume. These features will be readilyunderstood by a review of the description of exemplary embodiments andthe drawings that illustrate them, as well as by a review of theassociated claims that define various aspects of the invention.

By way of example, the present invention provides a modular approach toa lubrication package. Certain components such as the filter and coolerare directly connected to a block that has connections to accept themand internal porting to establish the proper flow paths for circulation,cooling and filtration of the circulating lubricant. The block canaccept one or more coolers and one or more filters. The isolationvalving for redundant equipment can also be integrated into the block.Many connections that had been used in past designs for the pipingnetwork are integrated into the block. The block can also be closemounted to the reservoir while a submersible pump further saves spaceand piping connections.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a plan view of a prior art lubricant circulation systemshowing the myriad connections and the space occupied;

FIG. 2 shows an exemplary block of the present invention used withtandem coolers and filters, in accordance with an embodiment of thepresent invention;

FIG. 3 shows an exemplary block of the present invention with a singlecooler and filter, in accordance with an embodiment of the presentinvention;

FIG. 4 shows an exemplary block of the present invention with a singlecooler and dual filters, in accordance with an embodiment of the presentinvention;

FIG. 5 shows the block of FIG. 2 mounted to a lubricant tank having asubmersible pump within and supported from a common plate as the block;and

FIG. 6 illustrates a transparent view of an exemplary block forreceiving various components, in accordance with an embodiment of thepresent invention.

DETAILED DESCRIPTION

Turning to FIG. 2, this figure illustrates an exemplary block 20 thathas been appropriately produced to include internal passages to properlyroute lubricant or coolant therethrough and in the proper order to theconnected components. There are two filters 22 and 24 that are directlymounted to the block with a gasket (not shown) that can be on the filteror on the block. The mounting method, for example, can be a spin ontechnique where the block features a threaded nipple that the filters 22or 24 spin onto. In doing the filter mounting this way, interconnectingpiping that used to connect the filters to the other components in thelubrication package will be eliminated. A valve that isolates one filterand lines up the other, preferably with a 90 degree turn of a handle 26extending from multi-port valves (not shown) can be used to block aninlet and outlet to one filter, such as 22, so it can be pulled off theblock 20 while the spare 24 is put in service. With proper alignment ofmulti-port valves in block 20, a 90 degree rotation, for instance, canquickly switch flow between filters with no piping external to block 20.

The coolers 27 and 28 are shown flush mounted to block 20. FIG. 3 showshow they can be connected quickly. Here a cooler 30 has four extendingbosses 32, 34, 36, and 38. Each boss has a ring gasket (not shown) atits upwardly oriented face for ultimate contact with a recessed sealingsurface (not shown) in the block 40. A typical boss such as 38 can havea recess or a flat 42 so that when the cooler 30 is fully advanced intothe block 40 the retaining rod 44 can be advanced to engage the recessor flat 42 to hold the cooler 30 securely to the block 40. Those skilledin the art will appreciate that there are alternative ways to secure thecooler 30 to the block 40. The unique feature is that they slidetogether with no interconnecting piping. That way they fit up fast, takeless space and provide fewer joints for potential leakage.

Referring back to FIG. 2, when there are multiple coolers 27 and 28,handles 46 and 48 can with a quarter turn operate tandem valvesrespectively on the oil side and the coolant side of the coolers 27 and28 to put either one or the other in service and to allow the other oneto be physically removed with lubricant and coolant still circulating,for instance. Here again the valving between the coolers is internal tothe block and is simple to operate for a change over and involves lessspace and fewer connections than packaged designs in the past.

Another feature is the incorporation of the thermal block 50 into theblock 20. Here again there is no piping external to the block 20 tosecure the thermal block 50 which serves as a lubricant temperaturecontrol with an internal bypassing of the particular cooler that is inservice done internally within block 20.

Additionally, pressure relief can also be incorporated into the coolerthat allows pressure on the discharge of the pump 52 go into a passageleading to the sump 54, both shown in FIG. 5. What can go into block 20is a relief valve 56 that can have inlet and outlet ports lined up withappropriate ports in the block 20 so that no external piping is requiredfor the relief circuit.

In the end, as shown in FIG. 2, there simply needs to be fourconnections made in the field for coolant in and out, which areconnections 58 and 60 and two others for the lubricant, only one 62being visible in FIG. 2.

FIG. 3 is simply a variation of FIG. 2 using 1 filter 64 and one cooler30. Using this layout requires equipment shutdown for servicing. Theother FIG. 2 concepts carry over to FIG. 3. The FIG. 4 design actuallyshows the four connections for coolant and lubricant and tandem filters66 and 68. In this design a filter change can be made on the fly butservicing the cooler 70 will require the equipment to be shut down.

FIG. 5 shows the variation of FIG. 2 mounted on a support plate 72 thatis secured to the sump 54 on sloping panel 74 with a generally flatbottom 73 that defines its footprint. As illustrated, the sloping panel74 is disposed at an acute angle 83 relative to the generally flatbottom 73. A support member 76 extends from plate 72 into sump 54 tosupport submersible pump 52. Having pump 52 inside sump 54 saves spaceas does the sloping panel 74 that makes room for the equipment describedin FIG. 2. Because of the sloping panel 74 the equipment such as coolers75 and 77 or filters 79 and 81 do not overhang the footprint 73.Additionally, inlet piping to the pump 52 is eliminated and the entireassembly is easy to service as it all comes out in one piece after theconnections, three of the four are shown.

Turing to FIG. 6, this figure illustrates some of the internal passages90 of an exemplary block 20. As illustrated, the filters 22 (see FIG. 2)can be secured to the filter receiving portion 92 of the block, at whichpoint the filters 22 will be coupled to the internal passages 90 of theblock 20. Thus, these passages facilitate modularized assembly of theunit without the need for unwieldy piping assemblies. Indeed, with theprimary plumbing network of the assembly defined by the internalpassages 90 of the block 20, parts can more easily be removed andreplaced when damaged. Moreover, components, such as the cooler 27 (seeFIG. 2), can be removed from one block 20 and placed on another block,as the components are modularized.

Those skilled in the art can see that the present invention allows forspace to be saved when packaging components particularly when redundantequipment is called for. While a lubrication system for rotatingequipment is illustrated, other systems can benefit from the modularconcept illustrated. Using the block and hooking up the equipment asdescribed not only saves space but reduces the number of connections andfacilitates rapid assembly of the skid in the field for hookup ofprocess or utility connections. Again, the block concept is particularlysuited to packages of equipment that are remotely assembled from wherethe unit is ultimately operated. While the certain embodiment encompassa lubrication assembly for a multi-stage centrifugal compressor, thoseskilled in the art will appreciate that the block concept can be adaptedfor lubrication systems for other types of rotating, reciprocating andmechanical requiring lubrication. Alternatively, the block can beintegral to a process equipment skid delivered to a remote location andcan allow a variety of process equipment to be compactly packaged whileminimizing external connections to the block while simplifying thepiping if not totally eliminating external piping between thecomponents. Diversion valving between redundant pieces of equipment canalso be configured internally to the block with extending handles whereeach handle can be used to turn inlet and outlet to one piece ofequipment while aligning its redundant into service. In some cases thiscan be done with a 90 degree turn on a single handle to isolatelubricant or coolant from one cooler to another. Also possible isreducing the conversion operations between coolers to a single handlethat can operate valves on both coolant and process sides of anexchanger in a single motion preferably 90 degrees. Filters or otherpairs of redundant equipment can be handled in the same manner. As analternative way to switch between redundant pieces of equipment shuttlevalves can be used within a block. An integrated piston can be mountedto the block to move a shuttle valve to change alignment between piecesof redundant equipment.

Referring again to FIG. 5, the ability to support all the equipment on asingle plate 74 allows for rapid installation and assembly or whenmaintenance is needed the entire module can be rapidly disconnected anda replacement installed to get a system back in service. Thus, apartfrom the space saving features of using a block, the furthermodularization of the components on a common base 72 facilitatesoriginal assembly or subsequent maintenance.

It should be further noted that the advantage of the block concept isthat process equipment can be mounted “directly” to it. In this context,mounting directly means that the equipment is received by the block in asealing relationship by bringing them together without the need toinstall intermediate piping or fittings. The process equipment isabutted or spun on and at most fasteners are used to secure the twotogether. The need for pipe fitters is reduced and the number ofconnections is also reduced as well as the volume occupied by the modulethat comprises the block and the process equipment connected to it.

While the preferred embodiment has been set forth above, those skilledin art will appreciate that the scope of the invention is significantlybroader and as outlined in the claims which appear below.

Again, the above description is illustrative of exemplary embodiments,and many modifications may be made by those skilled in the art withoutdeparting from the invention whose scope is to be determined from theliteral and equivalent scope of the claims below.

1. A lubrication processing apparatus for assembling equipment in amodule, comprising: a solid object having at least one exterior surfaceadapted to sealingly and directly accept a plurality of lubricationprocessing equipment, said object formed having passages therein, withat least some passages extending to said at least one exterior surfacefor fluid communication to said plurality of lubrication processingequipment, said object removably coupled to a base plate in fluidcommunication with a lubrication sump, said sump having a substantiallyflat bottom defining a footprint and a sloping wall to accept said baseplate such that said lubrication processing equipment does not overhangoutside of said footprint, said base plate supporting at least one pumpthereon.
 2. The apparatus of claim 1, wherein: said at least oneexterior surface is adapted to accept redundant equipment and at leastone valve, wherein said at least one valve is capable of isolating oneof at least two redundant equipment and put another in flowcommunication with said passages.
 3. The apparatus of claim 2, wherein:said at least one valve is operable by at least one actuator mounted tosaid at least one exterior surface of said object.
 4. The apparatus ofclaim 3, wherein: at least one control device is mounted in saidpassages with the ability to selectively divert flow therein.
 5. Theapparatus of claim 1, wherein: said object comprises at least onelubricant cooler directly mounted thereto.
 6. The apparatus of claim 5,wherein: said object further comprises at least one lubricant filterdirectly mounted thereto.
 7. The apparatus of claim 6, wherein: said atleast one pump is submersible and mounted to an opposite side of saidbase plate from said object and within said sump.
 8. A modularlubrication system for rotating or reciprocating equipment, comprising:a sump having an opening thereon; a lubrication module mounted to a baseover said opening and receiving lubricant circulation, cooling andfiltration equipment thereon; said sump comprising a generally flatbottom defining a footprint and said opening disposed on a sloping wallsuch that said circulation, cooling and filtration equipment does notoverhang outside of said footprint.
 9. The system of claim 8, wherein:said circulation equipment is mounted to said base within said sump. 10.The apparatus of claim 8, wherein: said lubrication module comprises athree dimensional solid object having an exterior surface adapted tosealingly and directly accept at least one of said circulation, coolingand filtration equipment, said object formed having passages therein,with at least some passages extending to said exterior surface, forfluid communication to said equipment.
 11. The apparatus of claim 10,wherein: all said circulation, cooling, and filtration equipment isdirectly connected to said object.